LAT Interface Survey Analysis Report

Transcription

1 LAT-TD LAT-TD TD September September LAT Interface Survey Analysis Report Martin Martin Nordby Nordby Ken Ken Fouts Fouts Catherine Catherine LeCocq LeCocq Dave Dave Rich Rich Marc Marc Campell Campell Robert Robert Ruland Ruland Mike Mike Gaydosh Gaydosh Arthur Arthur Scholz Scholz LAT-TD

2 Revision History Rev 02: Revision Information and Supporting Documents 13 Sep 2006: added ACD, final Radiator panel, and X-LAT Plate dimensional inspection data from NRL inspections after thermal-vacuum testing 23 Aug 2006: added heat pipe data and stayclear envelope survey checks; added heat pipe data and stayclear checks; changed name and scope to include only surveys supporting interface verification (was LAT Final Survey Results ) 13 Apr 2006: added E-box third layer and EMI Shield flatness/step height survey data and conclusions Supporting Documents LAT-DS-00851, TKR-LAT Interface Definition Drawing LAT-MD-00895, LAT Survey Plan LAT-MD-03566, Tracker Tower Assembly and Alignment Plan LAT-MD-01196, LAT Dynamics Test Plan LAT-DS-01221, Radiator Interface Definition Drawing LAT-DS-00040, LAT Envelope Drawing Other documents containing survey results LAT-TD-06368, Grid Survey Analysis Report LAT-TD-08509, LAT Internal Features Survey Analysis Report All dimensions in millimeters (mm) unless expressly shown otherwise LAT-TD

3 Outline Section Page 1. Introduction and Compliance Summary 2 2. SC-LAT Interface Features 7 3. LAT Alignment Fiducials LAT Instrument Interfaces and Envelope Verification Radiator Interfaces and Envelope Verification Conclusions 35 LAT-TD

4 Introduction This documents compliance with LAT dimensional and interface requirements The following chart lists all dimensional and interface requirements needing verification, the results of verification surveys, and a cross-reference to the chart containing the compliance details This document contains the survey data and compliance analysis The reference numbers (e.g.: C17) identify the data product and refers back to the initial definition of that data item in LAT-MD-00895, the LAT Survey Plan Note that not all data products called out in the LAT Survey Plan are delineated in this document Only those data products related to the verification of an interface are included LAT-TD

5 Summary of LAT Interface Verification Results Verif ID Req ID Topic Requirement Text Inspections Req'd Page Comply LVP119 LPS355 LVP381 LPS1134 LVP38 LPS351 LVP118 LPS353 LVP136 LPS415 LVP339 MEC3-117 Instrument Interface Surface LAT Alignment Features Mechanical Envelope LAT Stay Clear Zone LAT Static Design Envelope Mechanical Systems Static Envelope LVP344 MEC3-172 LAT Alignment The LAT shall interface to the Instrument Interface Structure using the mounting locations as shown in IRD Figure A-1. S/C I/F size & locations 8, 11 Use As-Is The LAT shall provide features as defined in LAT-Spacecraft ICD (doc # 1196 EI-Y C) Appendix A to provide measurement of the LAT coordinate Tooling holes, S/C pads 19 Provided system. The maximum static dimensions of the LAT shall be constrained as defined LAT & Radiator in the LAT-SC IRD, Figure A-1. envelope 22, 23, 24 Comply The LAT shall not violate the static stay-clear dimensions defined in drawing A-1. The dimensions define the maximum envelope available for the LAT & Radiator instrument for static design purposes, and margin to allow for dynamic envelope 22, 23, 24 Comply instrument motions under load. The SC will accommodate the LAT s thermal radiators, as shown in drawing Figure A-1, and described in the following subparagraphs. Figure A-1 shall define the static design envelope for the LAT hardware, and the SC will allow for the LAT's violation of this envelope under load, as negotiated and documented in the SC-LAT ICD. Mechanical Systems components and assemblies, including Radiators, shall stay within the static envelope, and not place other subsystem components outside said envelope, as defined in the IRD, Appendix A. [same as IRD Ver: I] LAT & Radiator envelope plus Ku's analysis that says we stay within dynamic envelope LAT & Radiator envelope The Grid structure with CAL, ACD, and TKR mounted, shall maintain alignment of subsystem interfaces to 30 arc-minutes with respect to the LAT Subsystem Interface Plane (LIP), after ground testing and launch. [derived from (TBD) measurements Ver: I] 22, 23, 24 Comply 22, 23, 24 Comply 25 Comply LAT-TD

6 Summary of Radiator Interface Verification Results Verif ID Req ID Topic Requirement Text Inspections Req'd Page Comply The LAT Radiator shall interface to the spacecraft provided Radiator Support LAT Radiator to Radiator - Strut I/F size LVP562 LPS425 Struts using the pad size and locations defined in IRD Figure A-1 View G-G 28 Comply SC Interface & locations of Appendix A. LVP141 LPS431 LAT Radiator Mounting The LAT radiators shall be supported by both the LAT and the SC. The SC- LAT-radiator mount point location(s) on each radiator shall be negotiated and documented in the SC-LAT ICD. Each SC-LAT-radiator mount point will allow complete translational freedom of movement in the plane of the radiator and complete rotational freedom of movement about the mount point. Rad strut pad locations 28 Comply LVP382 LPS1136 LVP137 LPS417 LVP139 LPS427 LVP138 LPS423 LVP140 LPS429 LAT Radiator The LAT shall provide threaded inserts for the strut mounting holes in the Radiator strut mount Mounting Inserts radiators. insert locations 28 Comply The SC shall accommodate, and the LAT thermal design shall be consistent with, a minimum radiating area for the LAT Radiators of 5.4 m2. This area shall be configured as two separate radiators, each with a minimum LAT Radiator Size radiating area of 2.7 m2, including the outward facing surfaces of the VCHP and Configuration reservoir volume. The radiators shall be no more than m wide, with a Radiator dimensions 30, 32 Comply stay-clear dimension of 54.5 mm to accommodate the thickness of the radiators and any attached MLI. Five cutouts are defined in View B-B of 433-IRD-0001 Appendix A. The Dynamic and radiators shall not encroach into these cutout volumes. The spacecraft Thermal Motion shall ensure that hardware penetrating through these cutouts maintains a Radiator dimensions 30 Comply Cutouts clearance to the envelope to accommodate all predicted dynamic and thermal relative motions. An additional stay-clear dimension of 59.5 mm, 48 mm on the outboard side VCHP Stay Clear and 11.5 mm on the inboard side, is included at the Z end of the radiators Radiator dimensions to accommodate the Variable Conductance Heat Pipes (VCHPs), as shown 33 Comply in View A-A of 433-IRD-0001 Figure The LAT radiators shall be nominally positioned as shown in drawing 433- IRD-0001, Figure A-1. The nominally flat radiating surfaces shall be LAT Radiator positioned parallel to the XZ-plane of the Observatory, to a tolerance Radiator location Positioning consistent with meeting the yaw-steering heat load requirement contained in 33 Comply the Spacecraft Performance Specification, 433-SPEC LAT-TD

7 2. SC-LAT Interface Features LAT-TD

8 Reamed pin holes SC-LAT Interface Holes: Reamed Pin Holes Pin holes were located using the drill template delivered by General Dynamics 3 out of 4 reamed pin holes are out of the tolerances shown on EIY D, the SC- LAT ICD (true position to [0.006 ]) Worst hole is out of tolerance by [0.001 ], radially All holes were fit-checked using the drill template supplied by General Dynamics, the mate of which was used to drill the flexure holes, thus their absolute position is not as important as how well they align with the tool LVP119 Conclusion: OK to use as-is LAT-TD

9 7/16-20 UNF tapped holes with keenserts SC-LAT Interface Holes: Tapped Bolt Holes These were drilled and tapped to tolerances on the Grid drawing LAT-DS Grid Machining drawing: 5 out of 8 holes are out of the tolerance shown on the Grid drawing (tolerance: true position to [0.008 ]) EIY D SC-LAT ICD: the same 5 out of 8 holes are out of the tolerance shown on the ICD drawing (tolerance: true position to [0.010 ]) Rationale for investigating the possibility of using the tapped holes as-is: hole positions with respect to the Flexures The flexures are mounted to the SC using the mating half of the LAT drill template, so the flexure reamed hole and LAT reamed pin hole centerlines will be very collinear Since the two mating reamed holes are aligned by definition, what matters most is that the position of the tapped holes in the Grid with respect to the neighboring pin hole in the Grid allows the bolt to fit through the clearance hole in the flexure, given its tolerances with respect to the neighboring pin hole in the flexure Analysis discussed on the following pages shows the relative alignment of these mounting hole features relative to the pin holes for both the Grid and Flexures, as well as the expected fit that results The conclusion is that all tapped holes align to their corresponding flexure holes, with margin, and can be used as-is LAT-TD

10 SC-LAT Interface Hole Details Methodology for analyzing relative hole locations Grid tapped hole and flexure clearance hole locations were calculated relative to the neighboring pin holes these as-built offsets are the vector difference between their global as-built locations The as-built relative locations are then subtracted from the nominal offsets of (from the ICD) this is the delta, or error in the hole s location from its nominal, relative to the neighboring pin hole (dx and dy) The as-built true position tolerance (TP) of the hole is calculated from the deltas this is the diameter of a circle with the nominal hole center at its center, and the as-built hole center on the circle. Thus, the radius of the circle is the root sum of the squares of dx and dy Finally, the as-built true position is added to the actual hole diameter to yield the apparent diameter this is the diameter that the feature would need to be if its center were at the nominal location and the perimeter just touched the perimeter of the real feature The apparent diameter of the tapped hole (which will contain a collinear screw) must be smaller than that of the clearance hole for the two to fit together subtracting the radii of these two apparent circles gives the expected minimum gap (margin) at the point of closest approach The table on the next page shows the expected gaps between the screw and the clearance hole in the flexure for each of the 8 hole locations LAT-TD

11 SC-LAT Interface Hole Analysis Summary The table shows that the minimum expected gap is [ ] The analysis that results in the gaps shown in the table use all as-built inspection data Grid: uses hole location inspection data from the Grid optical survey Flexures: uses hole location and diameter inspection data of the flight flexures The survey established hole locations by making a best-fit circle of the inside of the keensert LVP119 Disposition Standard deviation of the fit was [0.001 ] or less for all but 1 hole All survey data was transformed into the Grid Coordinate System, which used the datum D and E holes in the Grid (same holes as those called out in the SC-LAT ICD) For all 8 holes, the expected gap size is more than six times larger than the survey precision OK to use as-is Use all Grid-SC interface holes as-is, with no further analysis or inspection needed See LAT-SC ICD, ICN #095 dated 24 August 2005 (dims in mm) Expected Gap Pin Hole Left Right P0 Hole (+X side) P1 Hole (+Y side) P2 Hole (-X side) P3 Hole (-Y side) LAT-TD

12 SC-LAT Interface Hole Detailed Analysis: +X Side Grid-SC Interface Hole Fit Summary of Gaps Between Bolt and Flexure Hole (uses Grid tapped hole and flexure through hole as-built dims) Print Date: 25-Aug-06 Data Date: 1/2-Apr-05 P0 Hole (+X side) Left Tapped Hole Center Pin Hole Right Tapped Hole X Y X Y X Y P0 Nom P0 Actual Delta (Act-Nom) T.P. Delta LAT-DS Grid T.P. Tolerance Tolerance from Grid drawing Pass/Fail FAIL --- FAIL EIY D ICD T.P. Tolerance Tolerance from ICD drawing Pass/Fail FAIL FAIL FAIL Grid Relative to Pin Hole Nom from nom pin hole Act from actual pin hole = tapped hole actual - pin hole actual T.P. Delta from act pin hole = 2* RSS(dX, dy) Screw max apparent diam from nom =Nom diam + T.P. diametral tolerance Flexure Relative to Pin Hole Nom from nom pin hole Same as nominals on Grid Act from actual pin hole Copied from 'Spectrum Flexure Survey Data' sheet T.P. Delta from act pin hole = 2* RSS(dX, dy) Flexure hole as-built diam Inspection data from Spectrum Hole min apparent diam from nom = (flexure hole as-built diam) - (T.P. diametral tol) Gap at screw and hole MMC (+)=gap Gap=(hole min apparent diam - screw max apparent diam)/2 Fit OK? OK OK LAT-TD

13 SC-LAT Interface Hole Detailed Analysis: +Y Side Grid-SC Interface Hole Fit Summary of Gaps Between Bolt and Flexure Hole (uses Grid tapped hole and flexure through hole as-built dims) Print Date: 25-Aug-06 Data Date: 1/2-Apr-05 P1 Hole (+Y side) Left Tapped Hole Center Pin Hole Right Tapped Hole X Y X Y X Y P1 Nom P1 Actual Delta (Act-Nom) T.P. Delta LAT-DS Grid T.P. Tolerance Tolerance from Grid drawing Pass/Fail PASS --- FAIL EIY D ICD T.P. Tolerance Tolerance from ICD drawing Pass/Fail PASS PASS FAIL Grid Relative to Pin Hole Nom from nom pin hole Act from actual pin hole = tapped hole actual - pin hole actual T.P. Delta from act pin hole = 2* RSS(dX, dy) Screw max apparent diam from nom =Nom diam + T.P. diametral tolerance Flexure Relative to Pin Hole Nom from nom pin hole Same as nominals on Grid Act from actual pin hole Copied from 'Spectrum Flexure Survey Data' sheet T.P. Delta from act pin hole = 2* RSS(dX, dy) Flexure hole as-built diam Inspection data from Spectrum Hole min apparent diam from nom = (flexure hole as-built diam) - (T.P. diametral tol) Gap at screw and hole MMC (+)=gap Gap=(hole min apparent diam - screw max apparent diam)/2 Fit OK? OK OK LAT-TD

14 SC-LAT Interface Hole Detailed Analysis: -X X Side Grid-SC Interface Hole Fit Summary of Gaps Between Bolt and Flexure Hole (uses Grid tapped hole and flexure through hole as-built dims) Print Date: 25-Aug-06 Data Date: 1/2-Apr-05 P2 Hole (-X side) Left Tapped Hole Center Pin Hole Right Tapped Hole X Y X Y X Y P2 Nom P2 Actual Delta (Act-Nom) T.P. Delta LAT-DS Grid T.P. Tolerance Tolerance from Grid drawing Pass/Fail PASS --- PASS EIY D ICD T.P. Tolerance Tolerance from ICD drawing Pass/Fail PASS FAIL PASS Grid Relative to Pin Hole Nom from nom pin hole Act from actual pin hole = tapped hole actual - pin hole actual T.P. Delta from act pin hole = 2* RSS(dX, dy) Screw max apparent diam from nom =Nom diam + T.P. diametral tolerance Flexure Relative to Pin Hole Nom from nom pin hole Same as nominals on Grid Act from actual pin hole Copied from 'Spectrum Flexure Survey Data' sheet T.P. Delta from act pin hole = 2* RSS(dX, dy) Flexure hole as-built diam Inspection data from Spectrum Hole min apparent diam from nom = (flexure hole as-built diam) - (T.P. diametral tol) Gap at screw and hole MMC (+)=gap Gap=(hole min apparent diam - screw max apparent diam)/2 Fit OK? OK OK LAT-TD

15 SC-LAT Interface Hole Detailed Analysis: -Y Y Side Grid-SC Interface Hole Fit Summary of Gaps Between Bolt and Flexure Hole (uses Grid tapped hole and flexure through hole as-built dims) Print Date: 25-Aug-06 Data Date: 1/2-Apr-05 P3 Hole (-Y side) Left Tapped Hole Center Pin Hole Right Tapped Hole X Y X Y X Y P3 Nom P3 Actual Delta (Act-Nom) T.P. Delta LAT-DS Grid T.P. Tolerance Tolerance from Grid drawing Pass/Fail FAIL --- FAIL EIY D ICD T.P. Tolerance Tolerance from ICD drawing Pass/Fail FAIL FAIL FAIL Grid Relative to Pin Hole Nom from nom pin hole Act from actual pin hole = tapped hole actual - pin hole actual T.P. Delta from act pin hole = 2* RSS(dX, dy) Screw max apparent diam from nom =Nom diam + T.P. diametral tolerance Flexure Relative to Pin Hole Nom from nom pin hole Same as nominals on Grid Act from actual pin hole Copied from 'Spectrum Flexure Survey Data' sheet T.P. Delta from act pin hole = 2* RSS(dX, dy) Flexure hole as-built diam Inspection data from Spectrum Hole min apparent diam from nom = (flexure hole as-built diam) - (T.P. diametral tol) Gap at screw and hole MMC (+)=gap Gap=(hole min apparent diam - screw max apparent diam)/2 Fit OK? OK OK LAT-TD

16 3. LAT Alignment Fiducials LAT-TD

17 LAT Alignment Fiducial Definitions The LAT Grid includes precision reamed holes that are used for establishing the location of the Grid and LAT coordinate systems The holes are used in conjunction with retro-reflector tooling balls and laser trackers to re-construct the location and relative positions of components on the LAT This is done by determining the XYZ-offset of each ball to the origin of the LAT Coordinate System The following charts show a map of the approximate locations of the reflector balls on the Grid, and a table detailing the actual, as-surveyed locations of the ball centers, relative to the LAT Coordinate System Note that the offset from the Grid Coordinate System to the LAT Coordinate System is mm along the Z-axis LAT-TD

18 Retro-Reflector Reflector Ball Location Map +Y Radiator R10 R08 R06 R05 Panel 8 R07 G1 E P1 R09 Panel 7 R11 R04 GCS +Y HIB HIB HIB EPU Panel 6 R12 R14 B12 B13 B14 B15 BCS +Y BCS +X B08 B09 B10 B11 H05 H08 H02 H11 B04 B05 B06 B07 R02 R00 Panel 1 R03 G0 P0 R01 Panel 2 B15 B14 B13 B12 SIU B11 B10 B09 B08 GASU GCS -X SIU PDU B07 B06 B05 B04 R13 P2 G2 R15 B00 B01 B02 B03 EPU HIB HIB EPU Panel 5 B03 B02 B01 B00 R17 R16 R18 R20 R22 R23 A Panel 3 R21 D P3 G3 R19 Panel 4 LCS +Y LCS +X LAT Top View B = Bay number G = Grid interface planes H = Holes at TKR interface P = Points at SC Mount shear pin R = Reflector ball hole locations -Y Radiator LAT Bottom View LCS +X LAT-TD LCS +Y

19 Retro-Reflector Reflector Ball Location Offsets LVP381 The table shows the location offsets of the retro-reflector balls to the LCS origin Note that the actual values only are needed to reconstruct the LCS All coordinates are to the center of a ball diameter, offset from the intersection of the reamed hole and spotfaced surface Grid Feature Locations Data Date: April 1-2, 2005 Sheet Rev'd on: 25-Aug-06 Print Date: 25-Aug-06 Item Grid Feature CS Actual Surveyed Coords X Y Z Grid Reflector Ball Holes D3 R00: +X Wing Top LCS D3 R01: +X Wing Bot LCS D3 R02: +X Wing Top LCS D3 R03: +X Wing Bot LCS D3 R04: +X/+Y RMB Top LCS D3 R05: +X/+Y RMB Bot LCS D3 R06: +Y Wing Top LCS D3 R07: +Y Wing Bot LCS D3 R08: +Y Wing Top LCS D3 R09: +Y Wing Bot LCS D3 R10: -X/+Y RMB Top LCS D3 R11: -X/+Y RMB Bot LCS D3 R12: -X Wing Top LCS D3 R13: -X Wing Bot LCS D3 R14: -X Wing Top LCS D3 R15: -X Wing Bot LCS D3 R16: -X/-Y RMB Top LCS D3 R17: -X/-Y RMB Bot LCS D3 R18: -Y Wing Top LCS D3 R19: -Y Wing Bot LCS D3 R20: -Y Wing Top LCS D3 R21: -Y Wing Bot LCS D3 R22: +X/-Y RMB Top LCS D3 R23: +X/-Y RMB Bot LCS LAT-TD

20 4. LAT Instrument Interfaces and Envelope Verification LAT-TD

21 ACD envelopes LAT Instrument Envelope Verification C1: Transverse location of ACD BEA outer extremity C2: Transverse location of ACD outer extremity above BEA X-LAT Plate and EMI Skirt envelopes C3: Z-dimension to bottom-most extremity of X-LAT Plate C4: Half-width of EMI Skirt recess behind SC Mount C5: Location of EMI Skirt back wall behind SC Mount C6: Location of step in EMI Skirt back wall behind SC Mount C7: Z-dimension of EMI Skirt recess step C8: X-dimension of extreme location of X-side EMI Skirts LAT-TD

22 ACD Envelope LAT instrument envelope dimensions were verified through a combination of surveying and hand measurement using a Romer arm Optical surveying established best-fit planes defining the location of each Base Electronics Assembly (BEA) cover Surveying was also used to find the most extreme point on each cover A Romer portable CMM was used to find the location of the tallest protrusion sticking above the surface of each BEA cover, both in the BEA region, and further forward at the ACD MLI interface above the BEA The cover extreme point and height of the tallest protrusion were added to arrive at a conservative boundary of LAT hardware This was compared with the stayclear value LVP38 As the table shows, in all cases there is at least 22 mm of margin to the LAT stayclear VP118 VP136 Conclusion: LAT instrument complies with its stayclears around the ACD VP339 ACD Base Elect Ass'y, Radiator Mnt Bkt, X-LAT Plate Coordinates with respect to the Grid Coordinate System; dimensions in mm Rev Date: 13-Sep-06 Print Date: 13-Sep-06 ACD Stayclear Survey Data Height of Height of Tallest Tallest Extreme Point off Point above Point BEA Plane BEA Best-Fit Plane LAT-TD Stay- Clear Min Margin Pass/ Fail C1, ACD BEA Outer Extremity C2 ACD +X BEA +Y Cover PASS ACD +X BEA -Y Cover PASS ACD +Y BEA +X Cover PASS ACD +Y BEA -X Cover PASS ACD -X BEA +Y Cover PASS ACD -X BEA -Y Cover PASS ACD -Y BEA +X Cover PASS ACD -Y BEA -X Cover PASS

23 EMI Shield Envelope The EMI Shield locations around the LAT were optically surveyed to establish best-fit planes for each surface, and identify the extreme point for each side The coordinate of each extreme point was compared with LAT stayclear allowables The width of the step-back in the EMI Shield for the SC flexures was measured with calipers LVP38 and compared with stayclear allowables LVP118 LVP136 Conclusion: LAT instrument complies with its stayclear around the EMI Shield perimeter LVP339 Center EMI Shield Position, Width Rev Date: 13-Sep-06 Coordinates with respect to the Grid Coordinate System; dimensions in mm Print Date: 13-Sep-06 C5 C6 Center EMI Shield Near X-LAT Plate Survey Data Best-Fit Plane Location Extreme Point NTE Margin Pass/ Fail EMI Shield +X PASS May 4, 2006 Survey EMI Shield +Y PASS EMI Shield -X PASS EMI Shield -Y PASS Center EMI Shield Near Grid Best-Fit Plane Location Extreme Point NTE Margin Pass/ Fail EMI Shield +X PASS May 4, 2006 Survey EMI Shield +Y PASS EMI Shield -X PASS EMI Shield -Y PASS Measured C4 Center EMI Shield Width Min Width Min Margin Pass/ Fail 12 Sep 2006 Romer arm measurements at NRL EMI Shield +X PASS EMI Shield +Y PASS EMI Shield -X PASS EMI Shield -Y PASS C7 Z-Dim of Center Dim of EMI Shield Step Lowest Pt NTE Margin Pass/ Fail 12 Sep 2006 Romer arm measurements at NRL EMI Shield +X PASS EMI Shield +Y PASS EMI Shield -X PASS LAT-TD EMI Shield -Y PASS 23

24 X-LAT Plate Envelope LAT instrument Z-dimension envelope under the X-LAT Plate was verified through a combination of surveying and hand measurement using a Romer arm Optical surveying established a best-fit plane and extreme Z-dimension for the X-LAT Plate surface A Romer portable CMM was used to find the location of the tallest protrusion sticking above the surface of the X-LAT Plate The X-LAT Plate extreme point and height of the tallest protrusion were added to arrive at a conservative boundary of LAT hardware on the underside of the LAT This was compared with the stayclear value The minimum margin from any hard point on the LAT to the LAT stayclear is 35.2 mm LVP38 LVP118 LVP136 Conclusions LVP339 LAT instrument complies with its stayclear under the X-LAT Plate LAT complies with all stayclear allowables on all sides of the instrument ACD Base Elect Ass'y, Radiator Mnt Bkt, X-LAT Plate Coordinates with respect to the Grid Coordinate System; dimensions in mm Rev Date: 13-Sep-06 Print Date: 13-Sep-06 Survey Data Height of Tallest X-LAT Plate Bottom Best-Fit Extreme Point off X- Stayclear Plane Point LAT Plate Stay-Clear Margin Pass/ Fail C3 Bottom hardpoint PASS 12 Sep 2006 Romer arm measurements at NRL Billowing MLI blanket PASS LAT-TD

25 LVP344 LVP344 LVP344 Subsystem Alignment Verification Verification of the 30 arc-minute subsystem interface alignment tolerance was performed by visual inspection 30 arc-minutes = radians = 8.73 mm tip / 1 meter length Inspection involved checking the degree of tip over the width of each interface feature Inspection results ACD interface The width of the ACD interface is 1.6 m, so the allowed rise = rad x 1600 mm = 14.0 mm The ACD interface is machined into the Grid, and met all LAT interface requirements with tolerances that were nearly two orders of magnitude less than this Conclusion: interface complies CAL interface The width of the CAL interface is mm, so the allowed rise = rad x mm = 3.3 mm The CAL interface is machined into the Grid, and met all LAT interface requirements with a 0.1 mm flatness tolerance over the entire width of the Grid Conclusion: interface complies TKR interface The height of the TKR is 640 mm, so the allowed tip of a TKR module at this maximum allowed interface alignment tolerance = rad x 640 mm = 5.6 mm The total gap between TKR modules is 2 mm, meaning that modules would need to collide for the interface alignment tolerance to be exceeded The test-verified LAT and TKR structural models predict relative motions between two TKR modules of mm, which is 20 times less than the interface alignment tolerance would allow Conclusion: interface complies LAT-TD

26 5. Radiator Interfaces and Envelope Verification LAT-TD

27 Interface mount holes Radiator Interfaces and Stayclear Verification C18: XYZ-coordinates to strut mount holes Radiator panel dimensions C9: Z-dimension to extreme-most bottom feature of Radiator C10: Z-dimension to top of VCHP reservoir region C16: X-dimension of panel half-width C19: XZ-coordinate of circular hole cut-out center C20: Circular hole cut-out diameter C21: XZ-coordinates of square cut-outs C22: Square cut-out width x height Radiator panel surfaces C11: Y-dimension of best-fit plane of panel FOSR surface C12: Flatness of panel FOSR surface C13: Y-dimension to VCHP reservoir outer extremity C14: Y-dimension to panel innermost surface C15: Y-dimension to VCHP reservoir inner extremity C17: Y-dimension to SC strut mount pads on Radiator inside LAT-TD

28 Radiator Interface Mount Holes LVP382 The Radiators interface to the spacecraft through sets of four holes where the spacecraft Y- support strut brackets mount to the backside of the Radiator The holes in the Radiator are comprised of a clearance hole in the facesheet doubler, with a tapped hole in a floating insert The clearance holes in the doubler were placed to a relatively loose tolerance and made large enough so that the floating insert could be positioned as needed, providing the ability to locate the tapped interface holes in the correct location The interface hole features and locations were verified in 3 steps First, the tapped holes were inspected to verify size and depth Conclusion: all tapped holes comply with interface requirement for thread and depth Second, the location of the clearance holes in the doubler surveyed and their offset from nominal were calculated Third, the offset was compared to the mm radial range of the travel of the floating insert if the offset was less than the radial range, then the insert could be moved to place the tapped hole exactly at the nominal location Interface hole inspection results (see the following chart for inspection details) Minimum margin on insert float is mm on the radial range of travel All holes and inserts comply with the interface position requirements Further margin and risk mitigation The SC brackets have considerable ability to move in X and Z (in the plane of the Radiator) since they are mounted on struts with rod-end connections Furthermore, functionally-identical MGSE struts have been mounted and used for supporting the Radiators during environmental testing of the LAT VP562 VP141 Conclusion: all holes comply LAT-TD

29 Radiator Interface Mount Hole Inspection Details Radiator Panel #1 (-Y) Radiator Panel #1 (-Y) Name Description Surveyed Dimension Nominal Dimension Radial Insert Surveyed Dimension Nominal Dimension Radial Insert SC Strut Mount Pads X (mm) Y (mm) X Y Delta Float Margin P/F X (mm) Y (mm) X Y Delta Float Margin P/F R_TBHole1M Center pin hole pad Clearance hole tolerance to Rad R_Hole11 Center bolt hole pad PASS PASS R_Hole12 Center bolt hole pad PASS PASS R_Hole13 Center bolt hole pad PASS PASS R_Hole14 Center bolt hole pad PASS PASS R_TBHole2M Center pin hole pad Clearance hole tolerance to Rad R_Hole21 Center bolt hole pad PASS PASS R_Hole22 Center bolt hole pad PASS PASS R_Hole23 Center bolt hole pad PASS PASS R_Hole24 Center bolt hole pad PASS PASS LAT-TD

30 Radiator Panel Dimensions Radiator panel dimensions were surveyed on the individual Radiators before integration Dimensions were surveyed with respect to the Radiator-LAT interface, and not the LCS All panel and cut-out dimensions were well within the maximum material condition limits set in LAT-DS-01221, Radiator Interface Definition Drawing The minimum margin of any panel dimension to its MMC boundary is mm See the chart on the following page for a detailed list of measurements and margins Since measurements were not made with respect to the LCS, an additional offset must be factored in, to account for rigid-body misalignment of the Radiator to its nominal location, with respect to the LCS Radiator offset must include dx, dz, and tilt angle If the sum of the effects of these three contributions is still less than the minimum margin to the MMC boundary, then we still have margin There is further margin, since all LAT-SC interface dims bound the LAT-Rad envelope Radiator rigid-body misalignments, based on optical survey of the Radiator Mount Bracket pin locations with respect to the LAT Coordinate System X: (0.222 mrads * 1503 mm long) = mm lateral swing/offset due to pin misalignment this is well within the X-margin on stayclear envelope Z: (0.222 mrads * mm wide) = mm z-direction dip of one corner this is well within the Z mm margin on stayclear envelope VP137 VP139 Conclusion: All Radiator panel dimensions comply with LAT-SC IDD envelope allowables LAT-TD

31 Radiator Panel Dimensions Compliance Table Radiator Panel Survey and Verification of Radiator IDD Dimensions Rev Date: 26-Jun-06 Dimensions are to an auxiliary Radiator coordinate system, defined below; dimensions in mm Print Date: 23-Aug-06 Results delivered 6-Jun-2006 This verifies Radiator interface dimensions off of LAT-DS-01221, but not to LAT interface dimensions +X: from hole to slot = raw survey data TP = true position tolerance +Z: positive normal to inside face of Radiator panel = value passes tolerance evaluation criteria Min = nominal is minimum allowed dimension +Y: follows right-hand rule = value fails tolerance evaluation criteria NTE = nominal is not-to-exceed dimension Radiator Panel #1 (-Y) Radiator Panel #2 (+Y) Surveyed Dimension Nominal Dimension Surveyed Dimension Nominal Dimension Name Description X (mm) Y (mm) X Y Tolerance Margin P/F X (mm) Y (mm) X Y Tolerance Margin P/F C9, 16 Panel Perimeter PanelCorner1 Outer top edge corner NTE PASS NTE PASS PanelCorner2 Outer top edge corner NTE PASS NTE PASS PanelCorner3 Outer bottom edge corner NTE PASS NTE PASS PanelCorner4 Outer bottom edge corner NTE PASS NTE PASS C19, 20 SADA Cut-Out R_CircleHole Center circle cut out TP PASS TP PASS R_HoleDiam Center circle cut out diam Min PASS Min PASS C21, 22 Launch-Lock Cut-Outs Center square cut out 1 Nom: Nom: R_Square11 Corner square cut out > PASS > PASS R_Square12 Corner square cut out > PASS > PASS R_Square13 Corner square cut out > PASS > PASS R_Square14 Corner square cut out > PASS > PASS Center square cut out 2 Nom: Nom: R_Square21 Corner square cut out > PASS > PASS R_Square22 Corner square cut out > PASS > PASS R_Square23 Corner square cut out > PASS > PASS R_Square24 Corner square cut out > PASS > PASS Center square cut out 3 Nom: Nom: R_Square31 Corner square cut out > PASS > PASS R_Square32 Corner square cut out > PASS > PASS R_Square33 Corner square cut out > PASS > PASS R_Square34 Corner square cut out > PASS > PASS Center square cut out 4 Nom: Nom: R_Square41 Corner square cut out > PASS > PASS R_Square42 Corner square cut out > PASS > PASS R_Square43 Corner square cut out > PASS > PASS R_Square44 Corner square cut out > PASS > PASS Nominal Dimensions Survey Data Offsets of -X Pin RMB Interface to Rad Pin X Face Y Pin Z Pin X Face Y Pin Z Pin-Pin Angle dx dz Coord Dim Coord Coord Dim Coord Dist (mrad) +Y Radiator, +X RMB Y Radiator, -X RMB Y Radiator, +X RMB Y Radiator, -X RMB LAT-TD

32 Radiator Panel Surface Area The ICD requirement defines a minimum radiating area for a Radiator as 2.7 m 2 This has been interpreted by the LAT as minimum area agreed to by the LAT for use as radiating surface Thus, compliance with this requirement can be demonstrated by the LAT by showing that the envelope dimensions provide at least this surface area, and that the LAT stays within this envelope The envelope dimensions must result in at least 2.7 m 2 If the LAT verifies its thermal performance with Radiators that stay within this envelope, then this requirement is met Inspection results Maximum available radiating area provided by the LAT stayclear dimensions of the LAT- SC ICD (1903 w x h) 4*(101.6 x launch lock cut-outs) pi/4 *(215.9 diameter SADA cut-out) 2 = m m m 2 = m 2 The previous two charts detail LAT Radiator compliance with the Radiator stayclear envelope The LAT Thermal-Vacuum Test Report demonstrates LAT thermal control capability with these dimensionally-compliant Radiators Thus, the LAT meets this requirement LVP137 Conclusion: complies LAT-TD

33 Radiator Panel Surfaces The Y- or out-of-plane dimension of the Radiator panels was surveyed on the FOSR (outer) side of each panel The survey was done with the Radiators in a free state, held at the two Radiator Mount Brackets only The SC interface struts were then mounted and adjusted to bring the four points into a plane parallel to the LCS XZ-plane The resulting panel surface numbers are shown in the table on the following page This represents the ideal location for the Radiators, with a surveyed maximum angle out of a plane parallel to the YZ-plane of only 32 microns over the width of the Radiators Radiators panels are flat and parallel to the YZ-plane to within the survey tolerance This adjustment and survey process was done prior to environmental testing, and was also used to verify the following: Radiator panels can be adjusted out-of-plane at the SC strut interface by up to +/- 4 mm The panels were in this bent state for all environmental tests, verifying this allowable value The +/- 4 mm adjustment range should be used as the not-to-exceed value for positioning the Radiator on the SC during Observatory integration The existing Radiator shims at the RMB are adequate as-is, and do not require thinning or tapering Hand measurements were performed to verify stayclears for VCHP reservoirs and Radiator panel thickness, with the results also shown in the chart on the following page VP138 VP140 Conclusions Radiator panel flatness and parallelism: OK Maximum allowed adjustment of Rad-SC struts from free state: +/- 4 mm Radiator Y-stayclears: All panel surfaces comply with LAT-SC IDD envelope allowables LAT-TD

34 Radiator Panel Surface Feature Details LAT Radiator Survey on the LAT at NRL Rev Date: 13-Sep-06 Coordinates with respect to the LAT Coordinate System; dimensions in mm Print Date: 13-Sep-06 Summary of LAT Radiator Survey of 6/28/06 and NRL inspection of 9/13/06 = raw survey data Radiator Panel Surfaces +Y Rad -Y Rad Not-to-Exceed Dim Margin P/F C11 Y-dim of extreme point on panel FOSR surface max PASS extreme Y-coord on the Rad outer surface Y-dim of best-fit plane of panel FOSR surface best-fit YZ-plane for outer surface of Rad C12 Flatness of panel FOSR surface peak-to-valley excursion of flatness from best-fit plane C13 Y-dim to VCHP reservoir outer extremity max PASS extreme Y-coord on outside of any of the reservoirs C14 Y-dim to panel innermost surface min PASS extreme Y-coord on inside of Rad, not incl velcro C15 Y-dim to VCHP reservoir inner extremity min PASS extreme Y-coord on inside of any of the reservoirs C17 Y-dim to SC strut mount pads: +X pad nom Y-dim to SC strut mount pads: -X pad nom LAT-TD

35 LAT Survey Program Conclusions All LAT interfaces and stayclear envelopes have been inspected This was performed through a combination of optical survey and conventional dimensional measurement Inspection was performed at both the sub-assembly and LAT assembly level All LAT interface and envelope features comply with interface requirements except the SC- LAT mounting hole locations at the Grid-Flexure interface Grid-Flexure hole fit-up has been analytically checked and verified in hardware using flightduplicate flexures This near-flight configuration was used for all LAT environmental testing The disposition is to use all as-is This is documented further in ICN #095 LAT-TD